A MECHANICAL DESIGN FLOW USING OPEN SOURCE TOOLS:

DEVELOPMENT OF PRESSURE TRANSDUCERS AS A CASE STUDY

D. Rodriguez Sanmartin,a, b A. Lawal,b P. Cooper,b G. Awcock,a S. Busbridge,a
a

The University of Brighton, Faculty of Science and Engineering, Lewes Road,

Brighton, BN2 4GJ, UK
b
PSM Instrumentation Ltd, Unit 3, Burrell Road, Haywards Heath, West Sussex,
RH16 1TW, UK
E-mail: D.RodriguezSanmartin@brighton.ac.uk

Abstract:
PSM Instrumentation Ltd. (PSM), a UK firm specialising in instrumentation for liquid level measurement
for the marine industry, and the University of Brighton are currently collaborating in a 2 year Knowledge
Transfer Partnership. Its aims include introducing new-to-company technologies into PSM, such as
alternative manufacturing methods and design tools, and to use them to design products which could
be taken from concept to commercialisation.
The development of Computer Aided Engineering (CAE) design and modelling tools has transformed
how research and development is carried out over the last decade. CAE platforms speed up
development of new products by using computer models, generally based on Finite Element Analysis
(FEA), which allow for the analysis of different physics such as thermal, stress and electromagnetic.
This result in more robust designs whilst also reducing the number of prototype iterations needed,
which reduces development costs.
Open source CAE platform, are now able to offer SMEs sophisticated and competent capabilities at
zero capital cost, although indirect cost such as learning how to use the tools would be initially
incurred. Therefore, open source tools pave the way to a scalable alternative to commercial packages,
such that CAE capabilities could be embedded within an SME as a result of a KTP.
This presentation describes a mechanical design flow using open source tools including:
the creation of 3D models for visualisation purposes;

finite element analysis (FEA) for the calculation of thermal and mechanical stresses;

visualisation of FEA result;

the generation of parts manufacturing drawings.

The development of a pressure transducer at PSM will be used as a case study to demonstrate how
open source tools were used in its development.
Keywords: Small to Medium Enterprises (SMEs), Knowledge Transfer Partnerships (KTP), Computer
Aided Engineering (CAE), Finite Element Analysis (FEA), Open Source software.

1. Introduction
The
development of
Computer Aided
Engineering (CAE) design and modelling tools
has
transformed
how
research
and
development is carried out over the last
decade. CAE platforms speed up development
of new products by using computer models,
generally based on Finite Element Analysis
(FEA), which allow for the analysis of different

physics such as thermal, stress and

electromagnetic. These methods result in more
robust designs which in turn reduce the number
of prototype iterations needed and thus reduces
development costs.
For Small and Medium Enterprises (SMEs)
commercial CAE platforms still represent a
costly option, which, at best, may limit access to
a sub-optimal number of licensed seats and/or

software modules, at worst, may deter them

completely from engaging with these powerful
tools. Open source CAE platforms, however,
are now able to offer SMEs sophisticated and
competent capabilities at zero capital cost,
though indirect cost such as learning how to
use the tools would be initially incurred. Thus
open source CAE tools could pave the way to a
scalable alternative to commercial packages,
such that CAE capabilities could be embedded
within an SME as a result of a KTP.
Developments in both commercial and Open
Source Platforms leave SMEs with three
possible scenarios for the incorporation of CAE
capabilities:
Procuring software licences to access a
CAE platform which would have upfront
cost capital expenditure in the region of
15-25k (per license) depending on the
design and modelling capabilities required;
Engaging on incorporation of Open Source
CAE capabilities, which would not require
an initial capital expenditure, but other
issues such as difficult access to support or
training, could be an issue. Also, for some
specialised applications, such as solving of
piezoelectric equations, open source tools
are
not
appropriate
compared
to
commercially available packages.
Commercial CAE

The third option would be to use a

combination of both, where different
software tools would be used at different
steps of the design / modelling process.

The Table 1 below shows a strengths,

weaknesses opportunities and threats (SWOT)
analysis for both commercial and open source
CAE platforms. The decision on whether to
incorporate a commercial, open source or a
combination of both would depend on the SMEs
objectives, both short and long term.
Risks or threats to an SME committing to the
procurement of commercial packages includes
obsolescence of the tools, either because the
tools themselves become obsolete or the
organization needs change. Also, if these tools
are not used to full capacity their procurement
would represent a waste of expensive
resources. On the other hand, open source
tools present the risk for the SME of not being
able to successfully handover projects unless
there is a strategy in place to do so as would be
the case of an SME engaging on a KTP project.

Open Source CAE

Strengths

Weaknesses

Strengths

Weaknesses

Support and training from

providers.
Access to off the shelf
Tailored capabilities.
Easier to achieve short
term goals.

Licensing costs (15-25k)

Licensing
cost
(to
increase
number
of
licences)
Expensive
packages
needed
to
solve
multidisciplinary
problems.

No
upfront
licensing
costs.
Free software updates.
Access
to
multi-disciplinary software
tools.
Unlimited
number
of
licenses.
Access to source code.

Lack of training / support.

Expertise
required
introducing
these
capabilities into an SME.
Tools
need
more
validation (slow).
Risk of under-delivering
on short term goals.

Opportunities

Threats

Opportunities

Threats

Leveraging
knowledge
and
experience
of
commercial companies.
Achieving short term
goals.

Obsolescence (licences
need to be renewed every
5-8 years).
Procured packages not
adapting to future SME
needs.
Waste
of
expensive
resources if not used.

Collaboration with other

open source users.
Developing
in
house
tailored tools.
Continuous improvement
of CAE capabilities.
Adaptability to changing
SME needs.

Project handover
Incompatibility
with
commercial packages.
Lack
of
specialised
personnel
on
these
packages.

Table 1: Strengths, Weaknesses, Opportunities and Threats (SWOT) analysis for commercial and Open
Source CAE platforms in the context of an SME.

The first part of the paper provides the context

of the KTP project and describes some of the
technical
challenges
involved
in
the
development of a pressure transducer. These
include the choices of technology and materials
and the different physical problems involved

such as stress-strain analysis and temperature

induced stress.
The second part describes a general design
process flow including:
the creation of 3D models for visualisation
purposes;

finite element analysis (FEA) for the

calculation of thermal and mechanical
stresses;
the visualisation of FEA results;
the generation of parts manufacturing
drawings.

The third part of the presentation explores the

scenario in which only open source tools are
used in the design and development process
and aims to demonstrate how this general
design process flow can be implemented using
open source tools, using the development of a
pressure transducer in the KTP project as a
case study.

2. Technical
challenges
involved in the design of a
pressure
transducer
for
marine environments
PSM Instrumentation Ltd. (PSM), a UK firm
specialising in instrumentation for liquid level
measurement for the marine industry, and the
University of Brighton are currently collaborating
in a 2 year research programme funded by a
KTP. Its aims include introducing new-tocompany technologies into PSM, such as
alternative manufacturing methods and design
tools, and to use them to design products which
could
be
taken
from
concept
to
commercialisation.
One of the aims of the KTP project is to
incorporate into PSM CAE capabilities which
would be used for the design of pressure
sensors. From a modelling perspective,
pressure sensors represent a challenging
problem because there are different physics
involved in their design such as the fluid
structure interaction between a diaphragm and
a liquid for which the pressure needs to be
measured. The deflection of the diaphragm is
them transform into other magnitude (such as a
change in capacitance, or resistance).
In addition, devices working in the marine
industry encounter very harsh environments
when deployed in the field. For example, they
can be exposed to substances such as crude
oil or seawater. They also need to meet
different legislation requirements to operate in
potentially explosive atmospheres (ATEX
legislation), and ensure they are immune to
electromagnetic interference (EMC).
Typical operation requirements of pressure
transducers for tank gauging applications are
shown in Table 2 below. A 1 bar sensor is being

used as an example, though in practice

different transducers would be used to cover a
wide range of pressures (from 0.1 to 10 Bar).
These include the specification of a proof
pressure, i.e. the pressure up to which the
transducer can be subject to without
compromising its performance.
Another requirement of pressure sensors is that
these should produce a measurement which is
independent of the specified temperature
o
o
range, typically between -40 C and +80 C for
PSM applications. This is achieved by
designing structures which have very low
temperature drifts, which can be achieved by
the selection of materials with very similar
thermal expansion coefficients.
All these design requirements, make pressure
transducers devices where the coupling of
different physics, such as pressure and
temperature, needs to be minimized at the
design stage and compensated for during the
device operation. In addition, the transducers
need to remain linear during their specified
pressure ranges.
Parameter
Pressure range
Proof Pressure
Burst Pressure
Accuracy
(@20C and 1Bar)

Values
0-1Bar
3Bar
10Bar
0.001Bar (0.1% of the pressure
range)

Operating temperature
range

-30oC to +80oC

Legislation compliance

ATEX, legislation on explosive

atmospheres
EMC, legislation on
electromagnetic compatibility.

Table 2: Typical technical requirements of a 1Bar

pressure
transducer
for
tank
gauging
applications. Pressure ranges for tank gauging
vary typically from 0.1 to 10Bar [1].

In terms of sensor design, these requirements

mean, independently of the transducer
technology used, that two problems need to be
addressed:
The repeatability of the device output for
the pressure range, independently of the
transducer technology used, in order to
maintain the resolution of the sensor.
Compensation for temperature induced
strain.
For example, in the case when a flat diaphragm
is used, the diaphragm will have a pressure
range for which it would behave linearly.
However, when the pressure applied is too

A transducer technology under evaluation in the

KTP project is the use of strain gauges, bonded
to the back of a diaphragm. The idea being that
changes in pressure would result in a change in
the resistance of the strain gauges.
The equations governing the deformation of an
ideal diaphragm is a well understood problem
and has a regular stress/strain distribution for
ideal structure. For example the strain gauge
manufacturer has an application note on this
subject[2]. This, together with the desirable
values of change in resistance in strain gauges
can be used to make a first guess of the
diaphragm key dimensions (thickness and
diameter).
Temperature induced strain is an undesirable
effect in pressure transducers which may occur
as a result of the strain generated due to
differences in the coefficients of thermal
expansion of different materials constituting the
transducer and/or when there is a mismatch in
temperatures between different regions of a
device. In terms of transducer design it ought to
be minimised in order to obtain a predictive drift
with temperature which can then be corrected
by the sensors electronics.
Common
strategies
to
minimise
the
temperature induced strain are:
The matching of the CTEs of the materials
involved in the design. For example, strain
gauges are commonly specified by their
manufacturers
to
match
different
substrates.
The mechanical decoupling of parts of the
sensor subject to temperature gradients, for
example corrugated diaphragms are used
for this purpose on the design of LVDT
(linear variable differential transformer)
based sensors.
In the case of real geometries where chamfers
and/or fillets are used for ease of manufacture,
the use of three dimensional models, combined
with FEA models can help to visualise and
predict the stress distribution. These, together
with characterisation data, could help to gain a
further understanding of the device during the
design process.

3. A general design process

flow
The previous section described common issues
which need to be addressed in the design of
pressure transducers.
A general design process is represented in
block diagram form in Figure 1. It consists of
three main stages: Concept generation;
prototype design; and manufacture and
prototype testing.

1. - Device concept
2. - Device Modelling
3. Is it feasible from a
manufacturing perspective?
Prototype
Iterations

high, the diaphragm will suffer a plastic

deformation and will not return to its original
position after the pressure is relieved.

Concept
Iteration
s

4. Device design
5. Prototype manufacturing
and assembly
6. Prototype characterisation
7. Lessons learned
8. Does the device concept
need refining?

Figure 1: A general design process including

concept
generation,
manufacturing
and
characterisation.

The first stage is the concept generation, which

can be validated using models of the device. At
this stage manufacturing issues, such as the
cost of manufacturing parts, need to be taken
into consideration. If unsuccessful the concept
needs to be rejected or modified and the
concept generation process iterated again.
The second stage is the device design and
manufacturing.
At
this
stage
detailed
manufacturing drawings and specifications of all
the elements need to be produced, and drawing
files adapted for the manufacturing processes
used produced (designs of silicon etching
masks, laser or CNC machining files, and
device parts and assembly drawings, are
examples of manufacturing processes which
may need to be considered). Once all the
elements of the prototype assembly are
manufactured, the prototype assemblies need
to be carried out.
The final step is device testing to verify that the
expected performance was obtained and to
explore how the device could be optimised.
After the device characterisation and the
analysis of results the device design and

manufacturing cycle can be iterated to produce

successive generations of prototype devices.
Advances in CAE over the last decade allow
detailed CAD drawings of geometry or a device,
to be meshed and then be analysed using Finite
Element Analysis (FEA). These numerical
methods can be used to solve complex
problems with coupled physics and/or the
complex geometries which would be difficult to
solve using analytical methods. FEA tools in
turn allow a higher number of iterations at the
design concept stage which has the effect of
reducing the number of prototype iterations
needed to obtain a device ready for
commercialisation
thus
reducing
the
development time and costs.

of multinational companies, such as EDF which

has developed the open source SALOME
platform over the last 10 years incorporating
open source tools[13].
A possible choice of open source design tools
that can be used for the design process
described on the previous section are
highlighted on the diagram below:

1. FreeCAD
Parametric drawings

Concept
Iteration
s

2. Salome

Also, Open Source FEA packages which are

also capable of solving multi physics problems
are available. These include ELMER which was
developed at the University of Finland [9],
CodeSaturne for CDF analysis developed by
the EDF group in France [10], and OpenFoam,
a CDD analysis tool developed by the Open
Foam foundation which is now part of the SGI
group, Fremont, US [11].

4. Implementing
a
design
process flow using open
source tools
The open source movement, originated by
Richard Stallman in 1983 with the goal of
creating a freely available Unix based operating
system, has been developing CAE tools which
are available under the General Public Licence
(GNU)[12]. Some of the best examples are
Elmer, an FEA package for the solving of
coupled physics and OpenFoam CFD. The
potential of these tools has caught the attention

Prototype
Iterations

Meshing

A number of FEA packages are commercially

available, and some examples are: ANSYS by
ANSYS Inc. Southpoint, US [3]; ABAQUS by
SIMULIA, a subsidiary of Dassault Systmes,
Providence, US [4]; COMSOL MultiPhysics by
COMSOL Ltd. US[5]; and LUSAS, a trade mark
of Finite Element Analysis Inc., Kingston upon
Thames, Surrey, UK[6]. Other tools such as
SolidWorks (Dassault Systmes SolidWorks
Corp, Concord, US)[7], which were previously
specialised on design incorporate now FEA
capabilities in their products. Commercial
packages tend to be specialized on particular
applications. Two examples are: LUSAS which
is used for civil engineering projects; and
PZFlex (Wiedlinger Associates Inc, US) [8]
which is used for prototyping of ultrasound
transducers and wave propagation analysis.

3. Elmer
Finite element analysis solver

4. ParaView
Visualization

5. NanoCAD
Manufacturing drawings

6. Prototype characterisation
7. Lessons learned
8. Does the device concept
need refining?

Figure 2: Open source tools that can be used for

the design and modelling of a pressure
transducer.

The design process would consist of:

Using FreeCAD to create parametric
models of the geometry under study which
can be easily modified.
Import models from FreeCAD into the
Salome platform using the industry
standard .step file format.
Define the domains (surfaces, volumes and
borders) of interest and create a mesh of
the part in Salome.
Export the meshed part from Salome into
Elmer using the .unv mesh file format.
Define boundary conditions and solver to
use in Elmer, linear elasticity and
temperature for example, and solve the
finite element analysis (FEA) problem.
Export the FEA results to ParaView using
the .vtk file format.
Analyse the FEA results in ParaView and
compare different simulation runs.
Finally, NanoCAD can be used to produce
CAD drawings, in the industry standard
.dwg file format, for the manufacturing of
parts.

FEA results would then need to be validated

using characterisation data obtained using
prototype devices to identify which areas of the
device would need further optimization.
These open source packages can be installed
on a single computer, though a dual-boot
technique to install Linux and Windows on the
same computer would need to be used due to
their operating system compatibilities as shown
in the Table 3 below:
Software
package

FreeCAD
(ver. 0.13)
(*)

Salome

(ver. 7.2.0)

Elmer
(ver. 7.0)

ParaView
(ver. 3.00.0)

NanoCAD
(ver. 4.5)

Linux

Windows

(Ubuntu)
32
64

(Vista or 7)
32
64

32

(OX)
64

Figure 3 below shows a possible way in which

the drawings of a part can be defined in
FreeCAD. By defining constraints on a section
of a part, an outline of the sections of the part is
produced which can then be revolved along an
axis to obtain a 3D model of the part. Changes
on constraints of the 2D sketch, will result in a
change of the 3D part, which allows for the
quick production of design variants.
a)

Mac

b)

c)

Table 3: Operating system compatibility for

FreeCAD, the Salome platform, paraView and
NanoCAD for Linux, Windows and Mac. (*) The
previous version of Salome was compatible with
Windows 32bit systems, but for the latest and
current version it will only be available for Linux.

Minimum
recommended
hardware
requirements for the above tools are: 2GB
RAM, 4GB of storage, 500MB of video memory,
and Pentium 4 processor or equivalent, which
can be readily accessible on low cost
computers. However, and depending on the
application, higher hardware requirements are
required when dealing with large data sets.

4.1 Using
the
FreeCaD
parametric modeller for
design evaluation
FreeCaD is a parametric modeller which can be
used to quickly draw 3D models of parts, and
be used for visualization purposes. Being a
parametric modeller means that the basic
components of a part are drawn and then
constraints are applied to them until the number
of degrees of freedom of the part is zero. The
advantage of this drawing technique is its
flexibility and the ability to very quickly produce
several design variations from the same
drawing, just by changing some of the
constraints applied to the part. This would be
more difficult to do using the GEOM module of
the Salome platform.

Figure 2: Drawings of a pressure port with a

grooved neck made drawn in FreeCAD. a)
Snapshot of some of the constraints used to
draw a section of the part. b) Section of the part
which was revolved around the vertical axis to
obtain the 3D part. c) Side view of the 3D part. c)
Isometric view of the 3D part.

One of the features of FreeCAD is that

drawings can be exported using step files, a
common standard for 3D drawings which can
be imported into other design tools. For
example, FreeCAD drawings can be imported
into the Salome platform when saved as step
files.

4.2 Finite
element
analysis
using open source tools
As described in the previous section, it is
important to understand both the pressure
induced strain, in order to predict the device
performance, and to minimise the temperature
induced strain.
Finite element analysis can be used to gain a
further understanding of these characteristics
for complex geometries where the use of ideal
models may not be suitable. FEA allows for the

analysis of different design options using

models and, combined with the analysis of test
results, can reduce the amount of iterations
needed in the prototyping phase of the design.
As previously described, Elmer, OpenFoam and
Code Saturne are open source FEA tools. They
all have in common the need to generate a
mesh representing the model purpose of the
study.
The approach proposed in this paper is to
import step files from the parametric FreeCad
modeller into the Salome Meca platform[13].
Once the model is opened in Salome the model
can be defined further, for example by defining
the boundaries which will be subject to changes
in applied pressure or temperature, and
defining the different materials in the part. The
mesh module of the Salome Platform can then
be used to generate the mesh files which can
be imported into a FEA modeller, such as
Elmer.

using the Mesh module of the Salome platform

can then be exported into Elmer using the .unv
mesh file format.
Once the geometry is imported into Elmer, the
multi-physics problem under study can be
defined. For example, Elmer allows for the
calculation
of
electromagnetic
fields,
stress/strain in linear elasticity problems and
temperature induced stress.
The final step of the FEA is the visualization
and analysis of the results. ParaView[14], which
is also included as one of the modules in the
Salome platform. ParaView is a very powerful
visualization package developed in the US for
the visualization of very large data sets which
can be used for analysing FEA data. Results of
the FEA in Elmer can be exported into
ParaView using the .vtk file format as shown in
Figure 4 below:

Figure 3 below shows how the part designed

using FreeCAD was meshed using the mesh
module of the Salome Platform.

Figure 3: Picture of a mesh produced using the

Salome Platform, where surfaces of interest have
been defined. The original drawings were
created in FreeCad and then exported to Salome
using the .step file format. In practice finer
meshes would be generated to carry out FEA.

Figure 4: Vonmises stress on a diaphragm

(0.2mm 24mm diameter), subject to a pressure
of 10Bar generated using Elmer and visualised in
ParaView. For visualization purposes a clipping
through the middle of the structure was used
and the displacements in the structure were
exaggerated by a factor of 50. The top picture
shows the whole of the pressure port and the
bottom picture a closed up view of the
diaphragm and the mesh used for the simulation.

The domains of interest, such as such as the

surfaces of the diaphragm and the volume of
the device are also defined at this stage so they
can be identified by the FEA modeller to assign
materials and boundary conditions such as
pressure or temperature. Meshes produced

The figure depicts the Vonmises stress on a

diaphragm (0.2mm 24mm diameter), subject
to a pressure of 10Bar and how the ParaView
can be used as a visualization to interrogate the
data. For example, in the figure a clipping
through the middle of the structure was used

and the displacements in the structure were

exaggerated by a factor of 50.

native .dwg support, an industry standard

interface, and an open architecture.

The model could be used to calculate the

stresses and strains in the structure for different
boundary conditions, such as applied pressure
or temperature, and to optimise the geometry of
the design such as the thickness of the
diaphragm. In addition the model could predict
what would happen if a different material was
used by changing the material properties used
in Elmer.

So far, NanoCAD has 100,000 users in Russia

and
is
now expanding
internationally.
Nanosofts business is based upon gaining
revenues by providing support and tailoring
NanoCAD for specific applications, in contrast
to the traditional approach of gaining revenues
for licensing.

4.3 Producing
manufacturing
drawings with NanoCAD Eng
NanoCad is an open source computer aided
design application released by the Russian
CAD vendor Nanosoft in March 2012. It has

An example of how NanoCAD was used during

the KTP project is shown in Figure 5 below,
depicting the CAD drawings that were used for
manufacturing and a picture of the part on the
insert. In particular, this part is being used as a
tool for manipulating test pressure ports during
machining and assembly.

Insert:
Picture of the
manufactured part

Figure 5: Example of a manufacturing drawing drawn using NanoCad Eng 4.5. In particular these
drawings were used to manufacture a fixture to assist with the handling of pressure ports. The insert
shows a picture of the manufactured part.

5. Summary and Conclusions

CAE platforms have changed design processes
over the last decade, reducing developing time
and costs. There are both commercial and
Open Source CAE platforms available. In some
industries, such as car manufacturers for the
modelling of vehicle aerodynamics have

adopted the strategy of using a combination of

commercial and open source software
packages to carry out their finite element
analysis.
A SWOT analysis of both commercial and open
source packages, which highlights that the right
choice for an SME would depend on its
organizational objectives. Licensing costs and
the risk of obsolescence being major issues for

commercial packages; whereas difficult access

to training and support the major disadvantage
of open source.

5.

A general design process and how it could be

implemented using open source tools has been
described. In the proposed design process the
parametric modeller FreeCad would be used for
design visualization and evaluation. FEA
analysis would be carried out using the GEOM
and mesh modules of the Salome platform for
the mesh generation, Elmer for solving multiphysics problems, and ParaView for the
visualization and analysis of the FEA results.
For the production of 2D manufacturing
drawings in the standard dwg file format, the
tool NanoCAD is being used.

6.

These tools can be used to simulate the effects

of different physics such as stress-strain and
pressure,
which
are
typical
problems
encountered on the design of pressure
transducers, which can help to optimise devices
at the design stage.

7.

8.

9.

10.

Finally, the KTP scheme can provide a platform

for the incorporation of open source CAE tools
into an SEM, as done in the project between the
University of Brighton and PSM instrumentation
for the development pressure sensors.

11.

6. Acknowledgements
The authors wish to thank Knowledge Transfer
Partnerships for funding the collaborative
project between PSM Instrumentation Ltd and
The University of Brighton (KTP 7864).

7. References
1.

2.

3.

4.

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2013; Available from:
http://www.psmmarine.com/docum
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(2010) Desing considerations for
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12.

13.

14.

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http://www.openfoam.com/. 2012
[cited 2012 01/04/2012].
GNU General Public Licence,
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